Vacuum Chamber

Airbag Inflator Helium Leak Test System

Overview

VTI’s Airbag Inflator Helium Leak Test System is engineered to provide safe and reliable fine leak testing for Units Under Test (UUT) of many different sizes.

This custom system is comprised of two completely independent leak test circuits with a shared PLC control system to allow asynchronous leak testing. The chambers are designed to be close fitting to the cylindrical part to minimize vacuum chamber volume and increase efficiency of the system. These chambers are interchangeable to allow flexibility to test different sized UUT. To ensure the test data matches the correct UUT, a stationary bar scanner is mounted inside of the light curtain to scan the UUT right before the leak test begins.

The control system is integrated with the customer’s database to provide real-time data. It is also interlocked with other equipment on the production line to guarantee testing requirements are met in production.

  • Product: Air Bag Inflator
  • Tracer Gas: Helium
  • Leak Reject Rate: 1 x 10⁻⁶ atm-cc/sec of Helium
  • TAKT Time: 15 Seconds
  • Pre-Charged: Yes
  • Pump Size: 13.9 CFM
  • Chamber Volume: Varys as Needed
  • Installation Date: 2005

Automotive Torque Converter Helium Leak Test System

Overview

VTI’s Automotive Torque Converter Helium Leak Test System is engineered to provide a fully automated, safe and reliable turnkey leak detection solution.

This fully automated system is comprised of two stations, the Pretest to find large leaks and the Helium Leak Test to find fine leaks. Two independently actuated grippers are used to load / unload the Unit Under Test (UUT). VTI’s SmartConnect fixtures are used to provide a reliable seal to the part and permit the evacuation, tracer gas fill, and venting of the UUT. When a UUT results in a pass it will be directed down the conveyer accordingly, if the UUT results in a fail it will be sent down a separate conveyor for further testing.

The control system is integrated with the customer’s database to provide real-time data. It is also interlocked with other equipment on the production line to guarantee testing requirements are met in production.

  • Product: Torque Converters
  • Tracer Gas: Helium
  • Leak Rate: 1.1 x 10⁻⁴ atm-cc/sec Helium at atm into vacuum
  • TAKT Time: 36 Seconds
  • Charge-In-Chamber
  • Blower Size: 706 CFM
  • Pump Size: 130 CFM
  • Chamber Volume: 3.85 ft³
  • Installation Date: 2013

Cantilevered Bottom-Up Pre-Charged Helium Leak Test System

Overview

VTI’s Cantilevered Bottom-Up Pre-Charged Helium Leak Test System is engineered to provide a reliable Helium Leak Test on medium sized slab coils.

The robust bottom-up style chamber door allows for easy, single operator use. This vacuum chamber allows for one or two units per test.

This system pictured is a refurbished machine. It originally leak tested fuel tanks for many years and now has been reconfigured for HVAC coils. This project demonstrates the longevity of VTI’s systems, and VTI’s willingness to work within a customer’s budget by refurbishing product instead of building new.

The control system is integrated with the customer’s database to provide real-time data. It is also interlocked with other equipment on the production line to guarantee testing requirements are met in production.

  • Product: Medium Slab Coils
  • Tracer Gas: Helium
  • Leak Reject Rate: >0.5 oz/yr of R-134a from 82 psig to atm
  • TAKT Time: 45 seconds
  • Pre-Charged: Yes
  • Blower Size: 1,600 CFM
  • Pump Size: 460 CFM
  • Chamber Volume: 24 ft³
  • Installation Date: 2019

Cart & Carrier Vertical Slab Coil Helium Leak Test and Handling System

Overview

VTI’s Cart and Carrier Vertical Slab Coil Leak Test and Handling System is engineered for easy product handling and reliable Helium Leak Testing of slab coils.

These custom product handling carts were designed to not only transport product around the manufacturing plant but also in and out of the brazing and leak testing systems with ease.

The front loading chamber has a horizontally translating door that can be manually opened or closed in order to not interfere with the product handling carts. The chamber is designed to sit close to the ground to allow ease of loading/unloading with product handling carts. When the leak test is complete the Unit Under Test (UUT) is ready to be evacuated or proceed with further testing.

The control system is integrated with the customer’s database to provide real-time data. It is also interlocked with other equipment on the production line to guarantee testing requirements are met in production.

  • Product: Slab Coils
  • Tracer Gas: Helium
  • Leak Reject Rate: > 0.5 oz/yr R-410A at 225 psig into atm
  • TAKT Time: 2 minutes
  • Pre-Charged: Yes
  • Blower Size: 1412 CFM
  • Pump Size: 460 CFM
  • Chamber Volume: 11 ft³
  • Installation Date: 2015

Dual 2 Volt Battery Cell Leak Test System

Overview

VTI’s Dual Battery Cell Leak Test System is engineered to provide reliable and efficient leak testing.

This robust top-down style chamber with cell presence sensors has the capability to test either one or two cells per cycle. Once in place, fixtures will be manually connected to the Units Under Test (UUT) which will control the evacuation, tracer gas fill, and venting of the UUT. This system is equipped with a pressure differential sensor to limit the cell wall pressure differential. This ensures the cell walls on the battery will neither explode or implode during evacuation and venting, resulting in a safe and reliable leak test solution.

The control system is integrated with the customer’s database to provide real-time data. It is also interlocked with other equipment on the production line to guarantee testing requirements are met in production.

  • Product: 2 Volt Batteries
  • Tracer Gas: Helium
  • Leak Rate: 1 x 10⁻⁴ atm-cc/sec Helium at 2 psia into Vacuum
  • Machine Time: 60 Seconds
  • Charge-In-Chamber
  • Pump Size: 130 CFM
  • Chamber Volume: 6.7 ft³
  • Installation Date: 2015

Hearing Aid Implant Helium E-10 Leak Test System

Overview

VTI’s Hearing Aid Implant Helium E-10 Leak Test System is engineered to provide exceptional leak testing for hearing aid implant manufacturing.

This custom system includes dual pneumatically actuated vacuum chambers to improve efficiency. The custom designed Stainless Steel leak test fixtures allow for leak testing in multiple stages of manufacturing. These fixtures are interchangeable to allow testing of multiple operations on the assembly line. The hardware and plumbing in this system is entirely made of metal, except the O-Ring that interfaces with the part, to achieve an extremely fine leak test of E-10. This system uses the “Outside-In” test (Charge hood volume) method to ensure reliable leak testing. This system and VTI’s expertise and attention to detail in leak testing helped to solve a serious problem with leaking Hearing Aid Implants in the field. After the first system, customer placed multiple orders to improve their manufacturing process.

The control system is integrated with the customer’s database to provide real-time data. It is also interlocked with other equipment on the production line to guarantee testing requirements are met in production.

  • Product: Hearing Aid Implants
  • Tracer Gas: Helium
  • Leak Reject Rate: 5 x 10⁻¹º atm-cc/sec from 2 atm into Vacuum
  • TAKT Time: 1.5 Minutes
  • Charge-In-Chamber
  • Pump Size: 3.5 CFM
  • Installation Date: 2009

Large Refrigeration Condensing Unit Helium Leak Test System

Overview

VTI’s Charge-In-Chamber Helium Leak Test System with Helium Recovery is engineered to provide a safely contained proof pressure test, evacuation, tracer gas charge, and fine leak test for condensing unit manufacturing.

This robust bottom-up style chamber door allows for ease of loading/unloading of Unit Under Test (UUT). Testing pressures vary from 125 psig to 400 psig to accommodate different specifications per customer request. After pressure decay test, the UUT is evacuated, then charged with Helium, and lastly leak tested to the customer specified leak rate all while in the vacuum chamber. VTI designed and built the pallet system for the customer’s manufacturing line.

The control system is integrated with the customer’s database to provide real-time data. It is also interlocked with other equipment on the production line to guarantee testing requirements are met in production.

  • Product: Condensing Units
  • Proof Gas: Air / Nitrogen
  • Proof Pressure: 400 psig
  • Tracer Gas: Helium Mix
  • Leak Reject Rate: 0.1 oz/yr R-410A from 86 psig into atm
  • TAKT Time: 300 seconds
  • Charge-In-Chamber
  • Blower Size: 11,330 CFM
  • Pump Size: 2,048 CFM
  • Chamber Volume: 139 ft³
  • Installation Date: 2017

Large Slab Heat Exchanger Charge-In-Chamber Leak Test System

Overview

VTI’s Large Slab Heat Exchanger Charge-In-Chamber Helium Leak Test System is engineered to provide a safely contained pressure decay test, evacuation, tracer gas charge and Helium leak test for slab coil manufacturing.

This robust bottom-up style vacuum chamber allows for easy, single operator use. Testing pressures vary from 80 psig to 1,000 psig to accommodate different specifications per customer request. After the pressure decay test, the Unit Under Test (UUT) is evacuated, then charged with Helium, and lastly leak tested to the customer specified leak rate. A Flow-Through test is incorporated in the test sequence to check for cross-circuiting of coils.

The control system is integrated with the customer’s database to provide real-time data. It is also interlocked with other equipment on the production line to guarantee testing requirements are met in production.

  • Product: Slab Coil
  • Proof Gas: Air or Nitrogen
  • Proof Pressure: 1,000 psig
  • Tracer Gas: Helium Mix
  • Leak Reject Rate: > 0.5 oz/yr R-410A at 225psig into atm
  • TAKT Time: 4 minutes
  • Blower Size: 1,600 CFM (X 2)
  • Pump Size: 460 CFM
  • Chamber Volume: 85 ft³
  • Installation Date: 2013

Missile Guidance Component Helium Leak Test System

Overview

VTI’s Missile Guidance Component Helium Leak Test System is engineered to provide reliable Helium leak testing.

This custom charge-in-chamber system is designed to Helium leak test to a reject rate of 3.0 x 10⁻⁵ atm-cc/sec. When the leak test results in a pass, the Helium in the Unit Under Test (UUT) will be evacuated and the vacuum bake-out at 25˚C to 60˚C will begin. The integrated vacuum bake-out system ensures all contaminants are driven out of the UUT before proceeding down the line. After the vacuum bake-out the chamber undergoes a cool down process until appropriate temperatures are met for handling.

The control system is integrated with the customer’s database to provide real-time data. It is also interlocked with other equipment on the production line to guarantee testing requirements are met in production.

  • Product: Missile Guidance Sub Assembly
  • Tracer Gas: Helium
  • Reject Leak Rate: 3.0 x 10⁻⁵ atm-cc/sec
  • TAKT Time: 5 Minutes
  • Charge-In-Chamber
  • Bakeout Temp: 25˚C to 60˚C
  • Pump Size: 17.7 CFM
  • Chamber Volume: 2.33 ft³
  • Installation Date: 2009

Packaged Unit Pre-Charged Helium Leak Test System

Overview

VTI’s Packaged Unit Pre-Charged Helium Leak Test System is engineered to provide reliable Helium leak tests for single packaged vertical Air Conditioning unit manufacturing.

This robust front loading style chamber has a sliding carrier tray to allow for easy load/unload of the unit. When the leak test is complete, with a pass, the Unit Under Test (UUT) is ready to be evacuated and moved down the line for further assembly.

The control system is integrated with the customer’s database to provide real-time data. It is also interlocked with other equipment on the production line to guarantee testing requirements are met in production.

  • Product: Single Packaged Vertical Unit
  • Tracer Gas: Helium
  • Leak Rate: 0.3 oz/yr R-410A at 230 psig into atm
  • TAKT Time: 62 seconds
  • Pre-Charged: Yes
  • Blower Size: 2,050 CFM
  • Pump Size: 500 CFM
  • Chamber Volume: 14.7 ft³
  • Installation Date: 2016

Residential Condensing Unit / Heat Pump Helium Leak Test "Cube"

Overview

VTI’s Residential Condensing Unit / Heat Pump Pre-Charged Helium Leak Test Cube is engineered to provide reliable Helium leak testing for residential condensing units.

This robust bottom-up style chamber door allows for ease of loading and unloading of Unit Under Test (UUT). The chamber door is lifted using a hydraulic 4-point lift method.  When the leak test is complete with a pass, the UUT is ready to be evacuated or proceed with further assembly.

The control system is integrated with the customer’s database to provide real-time data. It is also interlocked with other equipment on the production line to guarantee testing requirements are met in production.

  • Product: 1-5 ton Residential Condensing Units
  • Tracer Gas: Helium
  • Leak Reject Rate: Equivalent to 0.3 oz/yr R-410A from 225 psig to atm
  • TAKT Time: 90 seconds
  • Pre-Charged: Yes
  • Blower Size: 11,335 CFM
  • Pump Size: 460 CFM
  • Chamber Volume: 57 ft³
  • Installation Date: 2017

Residential Unit Refrigerant Leak Test System "HounDog Cryocube"

Overview

VTI’s HounDog Cryocube Refrigerant Leak Test System is engineered to provide reliable Refrigerant R-410A Leak Testing for condensing unit manufacturing.

This robust bottom-up style chamber door with gravity conveyors allows for easy load/unload. When the leak test of the vapor charged Unit Under Test (UUT) results in a pass, the UUT then receives the remainder of the R-410A charge and proceeds with further assembly.

The control system is integrated with the customer’s database to provide real-time data. It is also interlocked with other equipment on the production line to guarantee testing requirements are met in production.

  • Product: Fully Assembled Condensing Units
  • Tracer Gas: Refrigerant R-410A
  • Leak Reject Rate: 0.3 oz/yr R410a from 220 psig into atm
  • TAKT Time: 90 seconds
  • Pre-Charged: Yes
  • Blower Size: 11,335 CFM
  • Pump Size: 460 CFM
  • Chamber Volume: 55.4 ft³
  • Installation Date: 2017

Small Condensing Unit Pre-Charged Helium Leak Test System

Overview

VTI’s Small Condensing Unit Pre-Charged Helium Leak Test System is engineered to provide reliable fine leak testing for small condensing unit manufacturing. ³

This front-loading style chamber has a slide out carrier tray for ease of loading and unloading Unit Under Test (UUT). When the Helium Leak Test is complete, with a pass, the UUT is ready to be evacuated and proceed with further assembly.

The control system is integrated with the customer’s database to provide real-time data. It is also interlocked with other equipment on the production line to guarantee testing requirements are met in production.

  • Product: Condensing Unit
  • Tracer Gas: Helium
  • Leak Reject Rate: 0.3 oz/yr R-410A from 230 psig into atm
  • TAKT Time: 62 seconds
  • Pre-Charged: Yes
  • Blower Size: 2,050 CFM
  • Pump Size: 460 CFM
  • Chamber Volume: 13.7 ft³
  • Installation Date: 2015

Submarine Battery Helium Leak Test System

Overview

VTI’s Submarine Battery Helium Leak Test System is engineered to provide reliable and efficient leak testing for Battery Manufacturing.

This robust top-down style chamber allows for ease of loading/unloading of the Unit Under Test (UUT). Once in place, a fixture will be manually connected to the UUT which will permit the evacuation, tracer gas fill, and venting of the UUT. This system is equipped with a pressure differential sensor to ensure the pressure inside the UUT and outside the UUT (Chamber) are within the customer requested pressure differential. This ensures the cell walls on the battery will neither explode or implode during evacuation and venting, resulting in a safe and reliable leak test.

The control system is integrated with the customer’s database to provide real-time data. It is also interlocked with other equipment on the production line to guarantee testing requirements are met in production.

  • Product: Submarine Battery
  • Tracer Gas: Helium
  • Leak Rate: 1 x 10⁻⁴ atm-cc/sec
  • Machine Time: 60 Seconds
  • Charge-In-Chamber
  • Pump Size: 130 CFM
  • Chamber Volume: 8.6 ft³
  • Installation Date: 2015

Under-Counter Sealed Ice Maker Pre-Charged Helium Leak Test System

Overview

VTI’s Helium Leak Test System is engineered to provide a Helium Leak Test for Ice Maker manufacturing.

This robust bottom-up style chamber has rollers on the door surface to allow for easy, manual operator load/unload. The Unit Under Test (UUT) is Pre-Charged using VTI’s Helium Charge Station. The product is indexed to the vacuum chamber leak test system. As the vacuum chamber is evacuated, progressively more sensitive leak testing occurs. The system will abort early if large leaks are detected. If no leak is detected the system automatically measures a NIST – traceable Calibrated Leak to preclude false acceptance.

The control system is integrated with the customer's database to provide real-time data. It is also interlocked with other equipment on the production line to guarantee testing requirements are met in production.

  • Product: Under-Counter Sealed Ice Maker
  • Tracer Gas: Helium
  • Leak Rate: Equivalent to 0.1 oz/yr of R-134a at 85 psig into atm
  • TAKT Time: 60 Seconds
  • Pre-Charged: Yes
  • Chamber Volume: 7 ft³
  • Installation Date: 2008

460 Gallon Diesel Fuel Tank Helium Leak Test System (HLTS)

Overview

VTI’s Diesel Fuel Tank HLTS is engineered to provide reliable leak testing for the production of welded steel and aluminum diesel fuel tanks.

This robust bottom-up style chamber door was designed to be level with the customer’s floor. This design allows for the Unit Under Test (UUT) to be easily loaded / unloaded onto a roll around cart. A pressure differential sensor is incorporated into this system to ensure the pressure differentials on the walls of the UUT are controlled to customer requested limits. This ensures the UUT will neither explode or implode during evacuation and venting, resulting in a safe and reliable leak test. This system is equipped with an 1,550 gallon capacity Helium recovery system to improve efficiency and conserve Helium.

The control system is integrated with the customer’s database to provide real-time data. It is also interlocked with other equipment on the production line to guarantee testing requirements are met in production.

  • Product: 460 Gallon Diesel Fuel Tank
  • Tracer Gas: Helium
  • Leak Rate: 1.2 x 10⁻⁵ atm-cc/sec from 5 psia into vacuum
  • TAKT Time: 10 Minutes
  • Charge-In-Chamber
  • Blower Size: 11,335 CFM
  • Pump Size: 495 CFM
  • Chamber Volume: 327 ft³
  • Installation Date: 2015

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